Projects

Science and Technology Case Studies

Bristol-Myers Squibb Company
Parenteral Manufacturing Center
Manati, Puerto Rico

Torcon was selected by long-time client Bristol-Myers Squibb (BMS) to complete the construction of a new 190,000 sq. ft. manufacturing facility in Manati, Puerto Rico. The Parenteral Manufacturing Center (PMC) was constructed as a two “cell” design, with each cell a self-contained multi-story sterile formulation and filling operation that feeds into a common packaging line.

The functional areas and appropriate support areas were constructed on the west side of the existing facility in Manati. The building expansion follows the esthetics currently on site through the use of precast and metal panel façade materials.

The filling-finishing operations in PMC occur on the second floor with actual open processes contained with proven barrier technology.  Each cell has its own process equipment train including formulation tanks, vial washer, dry sterilization tunnel, filler, capper, and external vial washer. Design throughput for vial filling is 300 vials per minute with sizes ranging from three to one hundred milliliters. Some vials will pass through a lyophilizer to produce a dry product with increased shelf life. Torcon installed four 380 sq. ft. lyophilizers as part of the project to support production operations.

The filled and sealed vials produced upstairs travel to the common packaging area on the newly renovated first floor—a 15,800 sq. ft. area within the existing BMS facility. This area features state-of-the-art packaging equipment such as automatic inspection systems, labelers, check weighers and cartoners. As necessary, product and/or raw material cartons will be stored in a fully automated/refrigerated warehouse with automatic retrieval capability.

The facility is designed to allow for eventual expansion to four “cells.” The utility systems reside on the first floor of the facility and are essentially dedicated to the fill area they serve. Utilities include USP water; water for injection; clean steam; and three gases—carbon dioxide, oxygen and nitrogen.   Similarly, air handler systems on the third floor are dedicated to individual cells.